Impact Resistant Sheet Material

ABSTRACT

The present invention provides an impact resistant sheet material that helps provide exterior walls of a building with resistance to impacts so that the building structure can meet building standards, such as the Miami-Dade County Large Missile Impact Test, for resisting impacts in high wind areas. In one embodiment, sheet material comprises an impact resistant layer that attached to fibrous substrate. The impact resistant layer provides impact resistance to the sheet material so that a wall structure employing the sheet material is able to successfully withstand an impact from a projectile comprising a 9 pound, 7 foot two-by-four (“2×4”) traveling at a speed of at least 34 miles per hour. The impact resistant sheet material may comprise a moisture vapor permeable, water-impermeable barrier layer having a hydrohead of at least 55 cm and a moisture vapor transmission rate of at least 35 g/m 2 /day. Such a sheet material is particularly useful in barrier applications, such as a house wrap.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/837,100, filed Aug. 10, 2007, the contents of which are bothincorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates generally to a sheet material and inparticular to an impact resistant sheet material.

BACKGROUND OF THE INVENTION

In regions that are susceptible to high winds, such as hurricane forcewinds, there is a strong desire and need to protect buildings fromimpacts resulting from wind-borne debris. For example, the state ofFlorida has set standards that buildings situated in High VelocityHurricane Zones (e.g., Miami-Dade and Broward Counties) must be providedwith protection against wind-borne debris caused by hurricanes. Inparticular, Miami-Dade County has implemented strict test protocols forwind-borne debris that require walls and building panels to withstandcertain impacts, such as large or small-missile impacts. A product isdeclared large-missile resistant if it can withstand various impactswith a piece of lumber weighing approximately 9 pounds, measuringtwo-by-four in size (“2×4”), and traveling at a speed of 50 feet persecond (34 mph). Products that are able to meet the Miami-Dade Countytest protocols are issued a Miami-Dade County Notice of Acceptance(NOA).

Various types of sheet materials have been used in the construction ofbuildings as a barrier fabric to block water and air while allowingtransmission of moisture vapor from the building interior. Theseso-called housewrap products are typically applied over the sheathinglayer of the building and beneath the exterior surface layer of brick orsiding. Generally, housewrap products are flexible, inexpensive, andrelatively easy to install. However, they typically offer little to noimpact resistance and are susceptible to being punctured or torn. As aresult, these products are unable to meet the Miami-Dade Countyrequirements for impact resistance.

To meet the Miami-Dade County impact-resistant requirements, variousproducts have been developed, such as steel or cementitious wall panels.For example, Miami-Dade County NOA No. 02-1216.01 describes an approvedimpact resistant wall panel comprising rib roll-formed galvanized steelthat is made by Reynolds Metal Co. This product is generally expensiveto produce and install, as well as being relatively heavy andcumbersome. Other commercially available products have been developedthat are directed to composite structures that include one or morecementitious layers, a foam core, and a reinforcing mesh. For example,U.S. Pat. No. 6,119,422 describes a multilayered impact resistantbuilding panel having an insulating foam core that is sandwiched betweena fiberglass mesh reinforced cementitious panel and a plywood sheet, andan impact resistant heavy and thick nylon mesh adhered between thecementitious panel and the foam core. These wall panels are alsoexpensive to produce and difficult to install.

Thus, there still exists a need for a product that can meet theMiami-Dade County impact-resistant requirements while being relativelyinexpensive and easy to install.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an impact resistant sheet material thatcan help provide a building structure, such as an exterior wall orpanel, with resistance to exterior impacts so that the buildingstructure can meet building standards, such as the Miami-Dade CountyLarge Missile Impact Test, for resisting impacts in high wind areas.

In one embodiment, the impact resistant sheet material comprises animpact resistant layer that is attached to a fibrous substrate. Theimpact resistant layer provides impact resistance to the sheet materialso that the sheet material is able to successfully withstand an impactfrom a projectile comprising a 9 pound, 7 foot two-by-four piece (“2×4”)of lumber traveling at a speed of at least 34 miles per hour withoutpenetration of the sheet material. In one embodiment, the impactresistant sheet material of the present invention has a puncturestrength of about 1500 to 7,500 psi; an Impact Resistance as measured bythe Free-Falling Dart Method of greater than about 0.7 pounds; and aMullen burst strength of about 175 pounds (lbs) or greater.

In some embodiments, the impact resistant layer comprises at least twopluralities of strands that extend in different directions and thatintersect and are bonded to each other at points of contact. In oneembodiment, the impact resistant layer includes a first plurality ofstrands that extend in a first direction, a second plurality of strandsthat extend in a second direction that is different than the firstdirection, and third and fourth pluralities of strands that both extendat an angle with respect to the first plurality of strands and areoriented at opposite angles with respect to each other so they intersecteach other in an X-like pattern. Preferably, the impact resistant layerhas a tensile strength of at least 445 Newtons and an elongation that isbetween 2 and 20 percent to thereby provide impact resistance to thesheet material so that the sheet material is able to successfullywithstand impacts from wind-borne debris.

In one particular embodiment, the present invention is directed to animpact resistant sheet material having a breathable barrier layer. Forexample, the impact resistant sheet material may comprise a moisturevapor permeable, air and water-impermeable barrier layer having ahydrohead of at least 55 cm and a moisture vapor transmission rate of atleast 35 g/m²/day. Such a sheet material is particularly useful inbarrier applications, such as a housewrap.

In one embodiment, the barrier layer comprises a breathable barrier filmthat is attached to a surface of a fibrous substrate, such as spunbondwebs, woven slit films, carded webs, meltblown webs, flashspun webs,woven, and extruded webs, and the like. Preferably, the barrier layercomprises a nonwoven substrate comprising polymeric fibers randomlydisposed and bonded to one another, and a microporous polymeric filmlayer overlying one surface of the nonwoven substrate and intimatelybonded thereto. In one particular embodiment, the film layer cancomprise a polyolefin that is extrusion-coated onto a nonwoven substratecomprised of substantially continuous spunbond polypropylene filaments.

In another embodiment, the present invention is directed to a safe roomthat can be used in a building structure to provide shelter to occupantsduring high wind storm so that the occupants can be sheltered fromwind-borne debris. For example, the safe room may comprise a roomdisposed in a building structure that has a plurality of walls that aresubstantially covered with the impact resistant sheet material so thatwind-borne debris is prevented from penetrating through the walls of thesafe room and striking the occupants therein.

In addition to providing the desired impact resistance, the impactresistant sheet material of the present invention can be designed to belightweight, flexible, and in some embodiments is able to be cut withconventional cutting instruments, such as a scissors. As a result, thesheet material can be used in a wide variety of applications and can berelatively easily installed to exterior walls in the same way thattraditional housewrap materials are applied. Further, it is unexpectedthat the use of the relatively lightweight and flexible sheet materialof the present invention is able to meet the requirements of theMiami-Dade County Large Missile Impact Test. This is particularly truebecause conventional materials utilized in such applications typicallyprovide impact resistance through rigidity and harness (e.g., corrugatedsteel sheeting or concrete/cinder block).

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view of a house that includes the impactresistant sheet material of the present invention and in which a portionof the siding has been removed to show the underlying impact resistantsheet material;

FIG. 2A illustrates a projectile impacting an exterior wall of abuilding that does not include the impact resistant sheet material;

FIG. 2B illustrates a projectile impacting an exterior wall of abuilding that does include the impact resistant sheet material;

FIG. 3 is a perspective view of an embodiment of the impact resistantsheet material in which the impact resistant sheet material includes afibrous layer to which an impact resistant layer has been attached;

FIG. 4 is a perspective view of an embodiment of the impact resistantsheet material in which the impact resistant layer comprises a pluralityof intersecting and interwoven strands that are arranged perpendicularto each other to form a grid-like pattern;

FIG. 5 is a perspective view of an embodiment of the impact resistantsheet material in which the impact resistant layer comprises a pluralityof intersecting and interwoven strands having a tri-axial pattern;

FIG. 6 is a cross-sectional side view of the impact resistant sheetmaterial of FIG. 4 taken along line 6-6 of FIG. 4;

FIG. 7 is a perspective view of a composite wall panel that includes asubstrate to which the impact resistant sheet material of the presentinvention has been attached;

FIG. 8 is a perspective view of a building in which the exterior wallsof the building are in ghost form to reveal an interior safe room thatis protected with an embodiment of the impact resistant sheet material;and

FIG. 9 is a perspective view of a wall panel that includes the impactresistant sheet material of the present invention and that was tested inaccordance with the Miami-Dade County Impact Resistance test protocols.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention is shown. Indeed, the invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

The present invention provides an impact resistant sheet material thatcan help protect structures, such as buildings, from damage that mayresult from impacts with wind-borne debris moving at relatively highrates of speed. In one embodiment, the impact resistant sheet materialcan help provide a building structure, such as an exterior wall orpanel, with resistance to exterior impacts so that the buildingstructure can meet building standards, such as the Miami-Dade CountyLarge Missile Impact Test, for resisting impact in high wind areas.Under the Miami-Dade County Large Missile Impact Test, a buildingstructure, such as a wall or panel, must be resistant to penetrationfrom the impact on the exterior side of the panel of a woodentwo-by-four (“2×4”), approximately eight feet long, weighing about 9pounds and moving endwise at 34 miles per hour. In order to pass theMissile Impact Test, the panel structure subjected to such an impactmust be able to withstand a cyclic pressure differential test in which avacuum pressure is applied to the panel structure before and after thepanel has sustained an impact from the test projectile. Under the cyclicpressure differential test, the wall panel must withstand at leastone-third of the total vacuum pressure applied to the panel prior to theimpact without failure. Specifics of the Miami-Dade County Large ImpactMissile Test are discussed in greater detail below.

FIG. 1 illustrates an embodiment of the present invention wherein theimpact resistant sheet material 10 is being utilized as a housewrap thatis attached to the exterior wall sheathing of a building 12 (e.g., ahouse). In the illustrated embodiment, a portion of the building'sexterior siding 14 has been removed to provide the reader with a view ofthe impact resistant sheet material 10. As discussed in greater detailbelow, the impact resistant sheet material is capable of absorbingimpacts from objects moving at relatively high rates of speed withoutpenetration. As a result, the impact resistant sheet material of thepresent invention helps prevent such objects from penetrating throughthe exterior walls of the building and entering into the building'sinterior space.

FIGS. 2A and 2B illustrate two similarly constructed exterior wallstructures with the exception that the exterior wall depicted in FIG. 2Adoes not include the impact resistant sheet material, whereas theexterior wall of FIG. 2B does include the impact resistant sheetmaterial of the present invention. In FIG. 2A, the exterior wall 16 of abuilding is in the process of being impacted by a wind-borne object 18,for example a piece of lumber, that is moving at a relatively high rateof speed. As shown in FIG. 2A, the exterior siding 14 of the buildingand the underlying structure offers little to no impact resistant to theobject. As a result, winds of sufficient strength can propel the objectthrough the outer exterior wall 16 of the building, which can result inthe object penetrating into the building's interior. As shown in FIG.2B, an exterior wall 16 that includes the impact resistant sheetmaterial 10 provides impact resistance to the exterior wall and helpsprevent the object 18 from penetrating through the exterior wall andinto the building. Although the force of the impact may damage someportions of the exterior wall, such as the siding 14 or stucco, theimpact resistant sheet material has absorbed much of the impact and hasprevented the object from penetrating through exterior wall of thebuilding. As a result, a wall structure employing the impact resistantsheet material of the present invention is capable of meeting therequirements of the Miami-Dade County Large Missile Impact Test and isparticularly useful in regions that are susceptible to high winds.

In housewrap and similar applications, it is generally desirable for theimpact resistant sheet material to be both vapor permeable and waterimpermeable while also providing a barrier to air infiltration. In thisregard, FIG. 3 illustrates an embodiment of the impact resistant sheetmaterial 10 in which the impact resistant sheet material includes animpact resistant layer 20 to which a barrier layer 22 is attached. Theimpact resistant layer 20 helps provide impact absorbing properties sothat the impact resistant sheet material 10 can sustain impacts fromobjects moving at relatively high speeds without rupture. As discussedin greater detail below, the barrier layer 22 may comprise a fibroussubstrate 24 that is moisture vapor permeable and impermeable to waterand air leakage. In some embodiments, the fibrous substrate may becoated with a breathable, liquid impermeable coating, such as a filmlayer. In other embodiments, the barrier layer may comprise acombination of a fibrous substrate and a breathable, water-impermeablefilm layer. For example, FIGS. 4 and 5 illustrate embodiments of theinvention in which the impact resistant sheet material 10 includes afibrous substrate 24 having an outer moisture vapor permeable,water-impermeable film layer 26 adhered on one side thereof and theimpact resistant layer 20 attached to the opposite side. In still otherembodiments, the impact resistant sheet material may be used without abarrier layer. These and other embodiments of the invention arediscussed in greater detail below.

Generally speaking, the breathability of the impact resistant sheetmaterial may be controlled as desired for the intended application ofthe materials. In barrier applications, such as a housewrap, it isgenerally desirable that the impact resistant sheet material has amoisture vapor transmission rate (MVTR) that is at least 35 g/m²/day at50% relative humidity and 23° C. (73° F.) (e.g., perm of 5 or greater),and more desirably an MVTR of at least 50. In one embodiment, the impactresistant sheet material has a MVTR that is at least 100 g/m²/day. Insome embodiments, the impact resistant sheet material may have a MVTR ofgreater than about 150 g/m²/day, more specifically greater than about300 g/m²/day, and even more specifically greater than about 500g/m²/day. Typically, housewrap applications do not require high moisturevapor transmission rates and will often have a moisture vaportransmission rate of less than about 2000 g/m²/day. It should beunderstood however that materials having higher moisture vaportransmission rates are equally within the scope of the invention. Inbarrier applications it is also desirable for the impact resistant sheetmaterial to be impermeable to air flow. Preferably, the impact resistantsheet material has an Air Leakage Rate less than 0.02 L/(s·m²), and moredesirably less than 0.015 L/(s·m²). Moisture vapor transmission and AirLeakage rates are measured in accordance with the test proceduresdescribed below under the section entitled “Test Methods.”

In some embodiments, the impact resistant sheet material preferably alsohas a Gurley porosity of at least 400 seconds and a hydrostatic head ofat least 55 cm. Gurley porosity and hydrostatic head are measured inaccordance with the test procedures described below under the sectionentitled “Test Methods.”

As discussed above, the impact resistant layer 20 provides sufficientimpact absorbing performance so that the impact resistant sheet material10 is able to meet the requirements of the Miami-Dade Large MissileImpact Test. Preferably, the impact resistant sheet material is able towithstand an impact of a two-by-four (“2×4”) piece of lumber weighingapproximately 9 pounds, traveling at a speed of 50 feet per second (34mph). For example, the impact resistant sheet material 10 is desirablycapable of sustaining an impact energy from a projectile, such as attwo-by-four (“2×4”), of at least 65 ft-lbs/sec/in² without permittingthe projectile to penetrate through the impact resistant sheet material.

Preferably, the impact resistant sheet material of the present inventionhas a puncture strength of about 1500 to 7,500 psi, and in particularfrom about 2000 to 6,000 psi, and more particularly from about 3,000 to5,000 psi. In some embodiments, the impact resistant sheet material hasan Impact Resistance as measured by the Free-Falling Dart Method ofgreater than 0.7 lbs, such as greater than 1 lb. and in particulargreater than about 2 lbs. In one particular embodiment, the impactresistance sheet material has an impact resistance of at least 1 to 5lbs, and more particularly, from about 2 to 4 lbs. The impact resistantsheet material of the present invention may also have Mullen burststrength of at least 100 lbs, and in particular greater than 300 lbs. orgreater than 500 lbs. Preferably, the impact resistance sheet materialhas a Mullen burst strength from about 100 to 750 lbs., and morepreferably from about 300 to 550 lbs. Impact Resistance according to theFree-Falling Dart Method, puncture resistance, and Mullen burst strengthare measured in accordance with the test procedures described belowunder the section entitled “Test Methods.”

As shown in FIGS. 3-5, the impact resistant layer 20 may comprise aplurality of intersecting strands (collectively referred to by referencenumber 28) that extend across a surface of the fibrous substrate and areattached to each other at points of contact. In one embodiment, theimpact resistant layer 20 comprises a plurality of substantiallyparallel strands that extend substantially in a first direction and asecond plurality of substantially parallel strands extending in a secondand different direction. As a result, the first and second strands arewoven or attached to each other at multiple points of contact to therebyform a strong and coherent scrim-like material. In some embodiments, theplurality of strands can be adhesively or thermally bonded to eachother. In one preferred embodiment, the first and second pluralities ofstrands are woven together to provide strength and integrity to theimpact resistant layer 20.

In the embodiments illustrated in FIGS. 3 and 4, the impact resistantlayer 20 comprises a first plurality of spaced apart parallel strands 30extending in a vertical direction (e.g. the machine or longitudinaldirection), and a second plurality of spaced-apart parallel strands 32extending in a horizontal direction (e.g. the cross or transversedirection) that are substantially perpendicular to each other, andthereby define a woven scrim layer having a grid-like pattern.Collectively, strands 28 intersect with one another and are bonded toeach other to form a strong and coherent scrim-like material that iscapable withstanding impacts from objects moving at relatively highrates of speed.

In an alternative embodiment, as shown in FIG. 5, the impact resistantlayer 20 may have a weave pattern in which the impact resistant layerincludes three or more pluralities of strands that are arranged andextend in three or more different directions with respect to each other.In the embodiment in FIG. 5, the impact resistant layer includes a firstplurality of strands 30 that extend in the vertical direction (e.g.,machine direction), a second plurality of strands 32 that extend in thehorizontal (e.g. cross direction) and two pluralities of strands 34, 36that both extend at an angle with respect to strands 30 and are orientedat opposite angles with respect to each other so they intersect witheach other in an X-like pattern 38. Pluralities of strands 34, 36 may beinterwoven with strands 30, 32 and each other so as to form a stronglywoven scrim material having high strength and low elongation.

In another embodiment, the impact resistant layer may have a triaxialweave pattern in which a first plurality of substantially parallelstrands extend in the longitudinal direction of the sheet material, asecond plurality of substantially parallel strands extend at an anglewith respect to the first plurality of strands that is between 45 and 85degrees, and a third plurality of substantially parallel strands extendat an angle with respect to the first plurality of strands that isbetween 95 and 135 degrees. The second and third pluralities of strandstypically extend at opposite angles with respect to each other so thatthe strands intersect each other to form an X-like pattern.

In yet another embodiment, the impact resistant layer comprises a firstplurality of substantially parallel strands that extend in thelongitudinal direction of the sheet material, a second plurality ofsubstantially parallel strands and a third plurality of substantiallyparallel strands that extend at opposite angles with respect to eachother and intersect each other to form an X-like pattern. In oneembodiment, the second plurality of strands extends at an angle withrespect to the first plurality of strands that is between 75 and 85degrees, and a third plurality of substantially parallel strands extendat an angle with respect to the first plurality of strands that isbetween 95 and 105 degrees. In some embodiments, the impact resistantlayer may include a second set of intersecting strands that extend atdifferent angles with respect to the first plurality of strands than thesecond and third plurality of strands to thereby define an impactresistant layer having two X-like patterns of strands that are ofdifferent size with respect to each other.

Other weaving patterns or numbers of strands may be employed in thepractice of the invention provided the resulting impact resistant layerhas sufficient impact resistance so that a wall structure employing theimpact resistant sheet material is capable of passing the Miami-DadeCounty Large Missile Impact Test. The number of strands per square inchmay range from about 5 to 50 strands per square inch, such as from 5 to40, 5 to 30, and 10 to 25 strands per square inch. For example, in theembodiment illustrated in FIGS. 3 and 4, the numbers of strands persquare inch may range from about 10 to 30, and desirably from about 15to 25, and more desirably from about 17-20. In the embodimentillustrated in FIG. 5, the number of strands per square inch may rangefrom about 5 to 20, and in particular from about 5 to 15, and moreparticularly, from about 7 to 10 strands per square inch. The strandsgenerally have a denier between about 500 and 1,500, with a denier ofabout 800 to 1,200 being somewhat more preferred.

In order to provide the desired impact resistance, it is generallyimportant that the strands comprising the impact resistant layer, andhence the impact resistant layer itself, have low elongation and hightenacity. Generally, it is desirable that the impact resistant layer haslow elongation in the cross and/or machine directions so that elongationof the impact resistant layer is maintained at a minimum level during animpact. For example, in some cases having a higher level of elongationmay permit an object impacting the impact resistant sheet material topass through, or at least partially through, a building structure beforethe impact resistant layer is able to sufficiently retard the object'sforward movement. It may also be desirable that the impact resistantlayer has at least some elongation in the machine and cross directionsso that upon being impacted by an object moving at a relatively highrate of speed, the impact resistant layer has some slight give due tothe impact. This slight give (elongation) allows energy from the impactto be distributed into the surrounding regions of the impact resistantlayer so that the total force of the impact is not localized only at thesite of impact. As a result, impact energies can be distributed intosurrounding regions of the impact resistant layer, which may helpprevent breakage of the impact resistant layer.

Generally, the desired amount of elongation will depend on the tenacityand number of strands in the area of impact. For example, strands havinga relatively higher tenacity are able to absorb greater impacts thanstrands having a lower tenacity. In one embodiment, the impact resistantlayer has an elongation that is at least 1%, and preferably greater than2%, 3%, 4%, 5% or more. In one particular embodiment, the impactresistant layer has an elongation in the machine and cross directionsthat is between about 2 and 20%, and desirably between 5 and 15%, andmore desirably between 5 and 12%. In one embodiment, the impactresistant layer has an elongation that is between about 6 and 10%, suchas from about 8 to 10%. In one embodiment, the impact resistant layerhas an elongation that is less than 20%, and in particular less than10%.

The impact resistant layer has a tensile strength that is generally fromabout 445 to 1800 Newtons (N). In one particular embodiment, the impactresistant layer has a tensile strength that is from about 500 to 1500 N,600 to 1200 N, or from about 800 to 1,000 N. In some embodiments, theimpact resistant layer has a tensile strength that is from about 600 to1,800, 1,000 to 1,800 N and from about 1,200 to 1,600 N. Percentelongation and tensile strength are measured in accordance with the testprocedures described below under the section entitled “Test Methods.”

The strands comprising the impact resistant layer can comprise a varietyof different materials, such as nylon, polyester, fiberglass, cutresistant fibers, such as aramids including Kevlar®, and combinationsthereof. Suitable polyesters may include polyethylene terephthalate,polytrimethylene, terephthalate, and polytributylene terephthalate. Inone embodiment, the impact resistant layer comprises a combination offiberglass strands and polyethylene terephthalate strands. For example,the impact resistant layer may include from about 50 to 95 wt % offiberglass strands and from about 5 to 45 wt % polyethyleneterephthalate strands. In some embodiments, the impact resistant layermay desirably comprise about 60 to 90 wt. % fiberglass strands and fromabout 10 to 40 wt. % polyethylene terephthalate strands, and moredesirably from about 75 to 85 wt. % fiberglass strands, and from about15 to 25 wt. % polyethylene terephthalate strands. Suitable materialsfor the impact resistant layer include scrim materials available fromMilliken Co., and Saint Gobain.

The impact resistant layer 20 and the barrier layer 22 are preferablybonded, adhered or laminated together to form a single composite.Preferably, the impact resistant layer 20 has a strong adherence to thebarrier layer 22 and/or fibrous substrate 24. As discussed in greaterdetail below, typical bonding and lamination procedures may includethose that involve adhering the impact resistant layer and barrier layertogether with or without an adhesive, or using heat, pressure or both tocombine these materials. In one embodiment, the impact resistant layer20 and the barrier layer 22 can be attached to each other with thermalbonding, adhesive bonding, and the like. The resulting impact resistantsheet material generally has a thickness of about 10 to 60 mils, and inparticular, from about 20 to 50 mils, and more particularly, about 30 to35 mils.

As noted above, the barrier layer 22 may comprise a fibrous substratethat is moisture vapor permeable and substantially liquid impermeable.In this regard, FIG. 3 illustrates an embodiment of the invention inwhich the barrier layer 22 comprises a fibrous nonwoven sheet materialcomprising a plurality of filaments and/or fibers that are thermallybonded to each other to form a strong and coherent web. In oneembodiment, the barrier layer 22 may comprise a spunbond nonwoven webcomprising flash-spun polyethylene plexifilamentary fibers that arethermally bonded to one another. An example of one such barrier fabricis Tyvek®, which is available from E.I. du Pont de Nemours and Companyof Wilmington, Del. (“DuPont”). In one particular embodiment, thefibrous substrate comprises a spunbond nonwoven that is formed ofsubstantially continuous polypropylene filaments, and is commerciallyavailable from Fiberweb™ and sold under the trademark Typar® or Tekton®.

Suitable materials for the fibrous substrate 24 may include a nonwoven,woven, or extruded webs. Suitable webs may include spunbond webs, wovenslit films, carded webs, meltblown webs, flashspun webs, and the like.In a preferred embodiment, the fibrous substrate comprises a nonwovenweb, such as spunbonded and centrifugally spun fabrics, and fabricscomprising discontinuous or staple fibers, such as carded staple fiberwebs, needlepunched nonwovens, hydroentangled webs and the like. Meltblown webs of continuous or discontinuous fibers also may be suitable.In one embodiment, the fibrous substrate comprises a high tenacitynonwoven fabric formed from polymeric fibers which are randomly disposedand bonded to one another to form a strong nonwoven web. Generally, itis important for the substrate to have high tenacity and relatively lowelongation in order to provide the strength and other physicalproperties required for a barrier material such as a housewrap. In oneparticular embodiment, the fibrous substrate comprises a spunbondnonwoven that is formed of substantially continuous polypropylenefilaments. Such a nonwoven is commercially available from Fiberweb ofOld Hickory, TN and sold under the trademark Typar®Housewrap orTekton®Housewrap.

With reference to FIGS. 4 and 5, embodiments of the invention areillustrated in which the barrier layer 22 comprises a fibrous substrate24 to which a breathable, substantially liquid impermeable coating layer26, such as a film layer has been adhered.

Preferably, the film layer 26 has a strong adherence to the fibroussubstrate 24, such that the film layer and the substrate are not subjectto delamination but instead are structurally combined with one anotherto form a composite material. Generally, the peel adhesion of the filmlayer 26 to the fibrous substrate 24 is at least 59 g/cm (150grams/inch), and preferably at least 78 g/cm (200 grams/inch). Mostdesirably, the adhesion is so great that the fibers of the substratewill tear or break before delamination will occur. Adhesion of the filmto the substrate is measured in accordance with the test proceduredescribed below under the section entitled “Test Methods.”

The thermoplastic polymer fibers or filaments comprising the fibroussubstrate 24 may contain pigments as well as chemical stabilizers oradditives for retarding oxidation and ultraviolet degradation, and forimparting other desired properties such as antimicrobial, antimold, orantifungal. Typically, the stabilizers and additives are incorporated inthe polymer at conventional levels, e.g., on the order of about 0.5 to2% by weight. Typical stabilizers may include primary antioxidants(including hindered amine-light stabilizers and phenolic stabilizers),secondary antioxidants (such as phosphates), and ultraviolet absorbers(such as benzophenones). The polymer composition of the fibers orfilaments may also contain a pigment to render the fibrous substrateopaque. In one particular embodiment, the fibers can be pigmented blackusing a black pigment, such as carbon black. If a white color isdesired, titanium dioxide pigment can be used at comparable levels, orblends of titanium dioxide, with carbon black or with other coloredpigments could be employed. The fibers or filaments are preferablycircular in cross-section, although other cross-sectional configurationssuch as trilobal or multilobal cross-sections can be employed ifdesired.

The fibrous substrate 24 generally has a basis weight of at least 40g/m², such as 50 g/m² or greater. In some embodiments, the fibroussubstrate may have a basis weight that is from about 60 to 140 g/m², andfor certain embodiments, a basis weight of from 80 to 110 g/m².

In one embodiment, the fibrous substrate has a grab tensile strength ofat least 178 Newtons (40 pounds) in at least one of the machinedirection (MD) or the cross-machine direction (CD). More preferably, thenonwoven substrate has a grab tensile strength of at least 267 N (60pounds) in at least one of the MD and the CD. High tenacity and lowelongation can be achieved by selection of a manufacturing process inwhich the polymer fibers of the nonwoven fabric are drawn to achieve ahigh degree of molecular orientation, which increases fiber tenacity andlowers fiber elongation. In this particular embodiment, themanufacturing process involves mechanically drawing the fibers by meansof draw rolls, as distinguished from other well-known manufacturingprocesses for nonwovens which utilize pneumatic jets or slot-drawattenuators for attenuating the freshly extruded fibers. Mechanicallydrawing the fibers may allow for higher stresses in the fiber to orientthe polymer molecules in the fibers and thereby strengthen the fibers.The drawing is carried out below the melting temperature of the polymer,after the polymer has cooled and solidified. This type of drawingprocess is conventionally referred to as “cold-drawing” and thethus-produced fibers may be referred to as “cold-drawn” fibers. Becausethe fibers are drawn at a temperature well below the temperature atwhich the polymer solidifies, the mobility of the oriented polymermolecules is reduced so that the oriented polymer molecules of the fibercannot relax, but instead retain a high degree of molecular orientation.The degree of molecular orientation of the fiber can be determined bymeasuring the birefringence of the fiber. Cold-drawn fibers of the typeused in the present invention are characterized by having a higherbirefringence than fibers attenuated by pneumatic jets or slot-drawattenuators. Consequently, the individual fiber tenacity of a cold-drawnfiber is significantly greater than that of a fiber which is attenuatedor stretched by pneumatic jets or attenuators of the type used in somespunbond nonwoven manufacturing processes.

In one embodiment, the film layer 26 of the impact resistant sheetmaterial 10 is a moisture vapor permeable and substantially liquidimpermeable polymeric film. Suitable materials for the film layer 26 mayinclude breathable polymeric films that are inherently permeable tomoisture vapor, such as a monolithic film, or microporous films. Thefilm can comprise a preformed film that is laminated to the fibroussubstrate, or may comprise a film that is coextruded onto the fibroussubstrate. Generally, the film layer can have a gauge or a thicknessbetween about 0.25 and 20 mils and, in particular from 0.25 mils, andmore particularly from about 1 to 5 mils. The film layer may be appliedto the fibrous substrate at a minimum basis weight of 25 g/m², and mostdesirably, from 30 to 50 g/m².

In the case of a microporous film, the microporous film layer may berendered microporous, and hence breathable, by mechanically stretchingthe film to create microporous openings therein, or by using oils,additives, contaminants, and the like that create a breathable materialvia phase separation within the film. Methods of mechanically stretchingthe film include passing the film through a pair of embossing rollers orpassing film through one or more intermeshing rollers that incrementallystretch the film and thereby create microporous openings in the film atthe points of stretching. The microporous film can also be mechanicallystretched by passing the film over a series of rollers in which adownstream roll is driven at a greater rate of speed than an upstreamroll.

Suitable polymeric materials for the film layer include nylons,polyvinyl chloride (PVC), polyvinyl alcohol (PVA), polyolefins, such aspolyethylene, polypropylene, metallocenes, and blends thereof, as wellas blends of polyolefins with other polymers. In a preferred embodiment,the composition from which the film layer 26 is formed is prepared byblending or compounding one or more thermoplastic polymers with suitableinorganic or organic pore-forming fillers and with suitable additives,stabilizers and antioxidants.

In one particular embodiment, the film layer 26 comprises a polymercomposition that includes at least one polyolefin polymer component,such as polypropylene, propylene copolymers, homopolymers or copolymersof ethylene, and copolymers such as ethylene vinylacetate (EVA),ethylene methyl acrylate (EMA) and ethylene acrylic acid (EAA), orblends of such polyolefins. The polymer composition may, for example,comprise 100% polypropylene homopolymer, or blends of polypropylene andpolyethylene. Suitable polyethylenes include low density polyethylene,high density polyethylene, linear low density polyethylene (LLDPE), andblends thereof. The polymer composition may also include other nonolefinpolymers.

Preferably, the polymer composition is blended with a pore-formingfiller that helps render the film microporous upon being mechanicallystretched. Generally speaking, the filler material may be any mechanicalpore-forming agent that does not adversely affect the properties of thepresent invention. Fillers that may be used in connection with thepresent invention include inorganic or organic materials. Examples ofthe inorganic and organic fillers include calcium carbonate, talc, clay,kaolin, silica, diatomaceous earth, magnesium carbonate, barium tocarbonate, magnesium sulfate, barium sulfate, calcium sulfate, aluminumhydroxide, zinc oxide, magnesium hydroxide, calcium oxide, magnesiumoxide, titanium dioxide, alumina, mica, glass powder, zeolite, silicaclay, acetyl salicylic acid, molecular sieves, ion exchange resins, woodpulp, pulp powder, ferrous hydroxide, borox, soda line, alkaline earthmetals, baking soda, activated alumina, etc. Calcium carbonate isparticularly preferred for low cost, whiteness, inertness, andavailability. Calcium carbonate is particularly preferred as apore-forming filler, and it is preferred that the calcium carbonate betreated with calcium stearate to render it hydrophobic and to preventagglomeration or clumping. Preferably, the pore-forming filler has aparticle size of no more than about 5 microns.

To achieve the high level of MVTR required for barrier applications,such as a housewrap, it is preferred that the polymer and pore-formingfiller blend comprise at least 20% by weight filler, and desirably atleast 40% by weight filler, and most desirably at least 50% by weightfiller. The polymer composition may also include additional colorants orpigments, such as titanium dioxide, as well as conventional stabilizersand antioxidants, such as UV stabilizers, hindered amine lightstabilizer compounds, ultraviolet absorbers, antioxidants andantimicrobials.

In one embodiment, the film layer 26 is extruded and laminated directlyonto the fibrous substrate 24 in a single process. For example, thefilm-forming polymer composition is heated and mixed in an extruder, andis extruded from a slot die to form a molten polymer film. The moltenpolymer film is brought directly into contact with the fibrous substrate24 and the molten film composition is forced into intimate engagementwith the fibrous web by directing the materials through a nip defined bya pair of cooperating rotating rolls formed between a metal roll and arubber roll. The fibrous substrate layer may be provided as a web, forexample supplied from a roll, and the film layer and the barrier layercomprising the combination of the fibrous substrate and film layer arepassed through the nip of the rolls to adhere the film layer to thesurface of the fibrous substrate. The barrier layer thus formed can thenbe subjected to stretching to render the film layer microporous.

As noted above, various stretching techniques can be employed to developthe micropores in the impact resistant sheet material 10. A particularlypreferred stretching method is a process known as “incrementalstretching”. In an incremental stretching operation, the sheet materialis passed through one or more cooperating pairs of intermeshing groovedor corrugated rolls which cause the sheet material to be stretched alongincremental zones or lines extending across the sheet material. Thestretched zones are separated by zones of substantially unstretched orless stretched material. The incremental stretching can be carried outin the cross machine direction (CD) or the machine direction (MD) orboth, depending upon the design and arrangement of the grooved rolls.Example of apparatus and methods for carrying out incremental stretchingare described in U.S. Pat. Nos. 4,116,892; 4,153,751; 4,153,664; and4,285,100, incorporated herein by reference. In one embodiment, thebarrier layer (i.e., the combination of the fibrous substrate and filmlayers) is incrementally stretched to a permanent elongation less thanabout 5%. The barrier layer can be incrementally stretched to apermanent elongation less than about 2%, more specifically less thanabout 1%. Alternatively, the barrier layer can be incrementallystretched without any permanent elongation of the material.

In a preferred embodiment, the barrier layer 22 comprises a spunbondnonwoven that is formed of substantially continuous polypropylenefilaments to which a polymeric film comprising polypropylene and about40 to 50 weight % filler is extrusion-coated. Examples of suchcomposites for the barrier layer are described in commonly assigned,copending U.S. Patent Publication No. 2004/0029469, the content of whichis hereby incorporated by reference.

After depositing the film layer on the fibrous substrate, the resultingbarrier layer can be rolled-up and the stretching can be carried out ina separate subsequent operation, or alternatively, the stretching can becarried out in-line with the extrusion coating operation. Afterstretching, the impact resistant layer can be adhered to a surface ofthe fibrous substrate opposite the film layer. As discussed above, theimpact resistant layer can be adhesively adhered to the fibroussubstrate. In some embodiments, the adhesive is applied only to thestrands comprising the impact resistant layer so that the fibroussubstrate and impact resistant layer are only bonded to each other atpoints of contact. This may be particularly useful in embodiments inwhich the adhesive has a lower than desired moisture vapor transmissionrate. In this regard, FIG. 6 is a cross-sectional side view of theimpact resistant sheet material 10 taken along line 6-6 of FIG. 4. Asshown, an adhesive material 40 is located between the impact resistantlayer 20 and the fibrous substrate 24 at points of contact between thetwo layers. In applications where it is desirable for the impactresistant sheet material to have breathability, the adhesive may belimited to only points of contact so that the surface of the fibroussubstrate has sufficient surface area so that a desired level ofbreathability is maintained. In other embodiments, it may be desirableto select a breathable adhesive so that application of the adhesive doesnot adversely affect the breathability of the impact resistant sheetmaterial.

Alternatively, the adhesive can be broadly applied to the fibroussubstrate, such as a coating. In embodiments where the adhesive isapplied as a coating, it may be desirable to select and an adhesive thatdoes not adversely affect the breathability of the impact resistantsheet material. It should be understood that adhesives having low MVTRscan be used in applications where breathability is not a concern.

A wide variety of adhesives can be used in the practice of theinvention, which may include hot melt adhesives, pressure sensitiveadhesives, UV cured adhesives, water-based adhesives, and the like Insome embodiments, the adhesive may also include additional agents suchas fire retardants, UV stabilizers, and the like.

The impact resistant sheet material can be subjected to heat in order todry the adhesive layer and thereby securely adhere the fibrous substrateto the impact resistant layer. In some cases, heating of the impactresistant layer can result in shrinkage of the film layer, which can inturn result in shrinkage of the microporous openings. Accordingly, careshould be given in selecting the temperature for drying the adhesivelayer. In some embodiments, it may be desirable to pre-stretch thebarrier layer (i.e., the combination of the film and fibrous substrate)prior to attaching the impact resistant layer. Pre-stretching increasesthe size of the microporous openings so that if shrinkage does occur,the microporous openings will still remain open and the breathibility ofthe film layer will not be adversely affected. For example, the barrierlayer can be pre-stretched so that its breathability is increased by upto 1, 2, 3, 4, or 5% prior to attachment of the impact resistant layer.

From the foregoing discussion, it should be apparent that the impactresistant sheet material of the present inventions can be used in avariety of different construction applications, such as housewrapmaterials, flashing, roofing underlayment, and the like. In someembodiments, the impact resistant sheet material can also be used toprotect objects such as trailers, boats, automobiles, and the like fromimpacts with wind-borne debris.

The impact resistant sheet material can be mounted on the exteriorsheathing of a walls structure in the same way conventional housewrapsheet material is applied. For example, the impact resistant sheetmaterial can be incorporated into a wall structure comprising aplurality of framing members, such as “2×4” studs, to which an exteriorsheathing, such as oriented strand board (OSB), plywood, or gypsum boardhas been attached. The sheathing can comprise a fiber insulation boardformed from one or more of mineral fibers such as glass fibers, rockwool fibers, slag fibers, organic fibers, ceramic fibers (e.g.,alumina), silica or basalt fibers that are resin bonded into a rigid orsemi-rigid board. The impact resistant sheet material can be secured tothe sheathing with a variety of different fasteners, such as staples,nails, and the like. The walls structure typically includes an outercladding that is provided on the exterior side of the impact resistantsheet material. The cladding can be concrete masonry, ceramic tiles,glass, treated wood panel, siding, fiber cement weather board, shingles,bricks, stucco or stone, or the like.

FIG. 7 illustrates another possible application for the impact resistantsheet material. In this embodiment, instead of being applied to theexterior sheathing of a completed building like a housewrap material,the impact resistant sheet material forms part of a composite panel 44comprising a substrate 46 to which the impact resistant sheet material10 has been attached. Substrate 46 can comprise a sheathing materialsuch as oriented strand board (OSB), plywood, gypsum board, and thelike. In some embodiments, substrate 46 can comprise an insulatingmaterial such as a mineral fiber material, including mineral fiberboard, polystyrene or other foam materials. The impact resistant sheetmaterial can be attached to the substrate with fasteners, adhesives, andthe like. In some embodiments, the impact resistant sheet material islaminated to the substrate. In one embodiment, a plurality of compositepanels 44 can be used to envelop a building structure and therebyprovide an exterior wall structure having moisture and air barrierproperties as well as impact resistance.

In additional embodiments, the impact resistant sheet material of thepresent invention can also be used advantageously in the construction ofso called “safe rooms” that can be used to protect specific interiorrooms or areas of buildings from objects moving at relatively high ratesof speed, such as wind-borne debris. In this regard, FIG. 8 illustratesa building 12 having an interior room 50 with a plurality of walls 52 towhich the impact resistant sheet material 10 has been applied. During awind storm, occupants of the building 12 can seek shelter in safe room50 from wind borne debris. Preferably, safe room 50 is located withinthe interior of the building that is spaced apart from the exteriorwalls of the building,

In embodiments wherein the impact resistant sheet material is utilizedto protect interior rooms, such as discussed above, the impact resistantsheet material does not necessarily have moisture barrier properties.For example, in this embodiment the impact resistant material mayinclude both the impact resistant layer and the fibrous substrate, andin some cases might not include a layer that could be considered amoisture barrier layer. Suitable materials for the impact resistantlayer and the fibrous substrate include those discussed above.

In some embodiments, the impact resistant sheet material may lackbarrier properties. For example, in one embodiment, the impact resistantsheet material may comprise the impact resistant layer that is attachedto a relatively open fibrous substrate.

Test Methods

In the description above and in the non-limiting examples that follow,the following test methods were employed to determine various reportedcharacteristics and properties. ASTM refers to the American Society forTesting and Materials, AATCC refers to the American Association ofTextile Chemists and Colorists, INDA refers to the Association of theNonwovens Fabrics Industry, and TAPPI refers to the TechnicalAssociation of Pulp and Paper Industry.

The following tests are hereby incorporated by reference.

Basis Weight is a measure of the mass per unit area of a sheet and wasdetermined by ASTM D-3776, which is hereby incorporated by reference,and is reported in g/m². Fabric thickness is measured in accordance withASTM D 1777—Standard Test Method for Thickness of Textile Materials(1996).

Air Leakage Rate is a measure of determining air leakage across aspecimen under specified differential pressure conditions across thespecimen. This test is carried out in accordance with ASTM E 283 and E2178.

Percent Elongation is a measure of the maximum elongation of a fabric atfailure when subjected to unidirectional stress. Percent Elongation isdetermined according to ASTM D 5034-95.

Grab Tensile Strength is a measure of breaking strength of a fabric whensubjected to unidirectional stress. This test is carried out inaccordance with ASTM D 4632—Standard Test Method for Grab Breaking Loadand Elongation of Geotextiles, 1991 (reapproved 1996).

Gurley Porosity is a measure of the resistance of the sheet material toair permeability, and thus provides an indication of its effectivenessas an air barrier. It is measured in accordance with TAPPI T-460 (Gurleymethod). This test measures the time required for 100 cubic centimetersof air to be pushed through a one-inch diameter sample under a pressureof approximately 4.9 inches of water. The result is expressed in secondsand is frequently referred to as Gurley Seconds.

Hydrostatic Head (hydrohead) is a measure of the resistance of a sheetto penetration by liquid water under a static pressure. The test isconducted according to AATCC-127, which is hereby incorporated byreference, and is reported in centimeters.

Impact Resistance Free-Falling Dart Method is a measure of the weightrequired to cause 50% of tested films to failure by impact from afalling dart under specified test conditions. Impact resistantFree-Falling Dart measurements are determined in accordance with ASTMD-1709, Method B2.

Miami-Dade County Large Missile Impact Test (Miami-Dade Protocolsl PA201, PA 202, and PA 203). Under this test the wall structure is impactedwith a two-by-four (2″×4″) board weighing 9 lbs. and traveling atapproximately 34 mph. To successfully past the test, at least threeseparate impacts are conducted and the wall structure must prevent theboard from both penetrating the wall structure or creating a significantopening.

Moisture Vapor Transmission Rate (MVTR) is determined by ASTM E 96,Standard Test Methods for Water Vapor Transmission of Materials; 1995,Procedure A.

Mullen burst strength is determined by ASTM D-3786, Standard Test Methodfor Hydraulic Bursting Strength of Textile Fabrics—Diaphragm BurstingStrength Tester Method.

Peel Strength is measured in accordance with ASTM D 2724.

Puncture strength is measured according to ASTM D-4833-88.

Tear Strength is measured in accordance with ASTM D 4533 (trapezoidaltear), tensile strength measurements are determined according to ASTM D5034-95.

Example 1

Typar® 3201, a spunbonded polypropylene nonwoven fabric produced byFiberweb of Old Hickory, Tenn., was used as the fibrous nonwovensubstrate for producing a high MVTR extrusion coated composite sheetmaterial. Typar® 3201 is a spunbond polypropylene nonwoven fabric havinga basis weight of 64 g/m², a thickness of 0.229 mm (9 mils), an MD grabtensile strength of 360 N (81 lbs.), a CD grab tensile strength of 329 N(74 lbs.), a trapezoidal tear strength of 165 N (37 lbs.) in the MD and151 N (34 lbs.) in the CD, and a Mullen burst strength of 379211 Pascal(55 psi.). This substrate was extrusion-coated with a polypropylenepolymer composition containing about 50 percent by weight calciumcarbonate filler. The polymer film was extruded onto the substrate at abasis weight of 30 g/m². The resulting composite was incrementallystretched in the CD.

After being incrementally stretched, the combination of the nonwovensubstrate and polymer film was stretched in the cross direction toincrease its breathability by about 5% percent. A scrim layer (i.e.,impact resistant layer) was then adhesively bonded to the surface of thefibrous substrate opposite the film layer. In this step, a water solubleadhesive was applied to the scrim layer. The scrim layer comprised acombination of fiber glass and polyethylene terepthalate strands,available from Milliken Co. The amount of adhesive applied was about 50weight percent, based on the total weight of the scrim layer. Theresulting sheet material was passed over a series of dryer cans toevaporate any excess water out of the sheet material. The drying stepwas performed at a temperature of about 100-110° C. Various propertiesof the resulting impact resistant sheet material are provided below.

TABLE 1 Properties of the Impact resistant Sheet Material Property Testmethod Units Value Hydrohead AATCC 127 cm 550 MVTR ASTM E 96-A g/m²/day60 Peel Strength ASTM D 2724 Lbs. 2.94 MD Tensile Strength ASTM D 4632Lbs./inch 233 MD Elongation ASTM D 4632 % 8.7 CD Tensile Strength ASTM D4632 Lbs./inch 191 CD Elongation ASTM D 4632 % 6.9 Thickness ASTM D 1777mils 21.3 Basis Weight ASTM D 3776 osy 7.6

The impact resistant sheet material also had a flame spread index of 25and a smoke developed index of 200, as measured in accordance with ASTME 84; a self-ignition temperature of 788° F., as measured in accordancewith ASTM D 1929; and a burning rate of 54 mm/min as measured inaccordance with ASTM D 635.

The impact resistance of the impact resistant sheet material of Example1 was compared to various barrier sheet materials. The results aresummarized in Table 2 below. The Samples described in Table 2 are asfollows:

Sample 1: Inventive impact resistant sheet material described in Example1, above.

Sample 2: Tyvek® Homewrap® available from Du Pont de Nemours andCompany;

Sample 3: Woven slit film available from Lowes Product No. LW1490LOW,white 9′×150′ rolls;

Sample 4: Breathable sheet material comprising a spunbond polypropylenesubstrate and an outer breathable, monolithic film layer, available fromFortifiber, under the trademark Weathersmart™;

Sample 5: R-Wrap produced by Covalence Coated Products (formerly LudlowCoated Products).

TABLE 2 Impact Properties of Inventive Sheet Material vs. VariousBarrier Sheet Materials Test Sample 1 Sample 2 Sample 3 Sample 4 Sample5 Test Method Free Falling Dart 2.27 <0.70 0.83 <0.70 — ASTM D 1709-4Impact Failure Weight (1bs.) (method B 2″ dart @ 60″) Average Thickness(mm)  0.669 0.076 0.108 0.265 — ASTM D 1777-75 Probe Penetration (psi)4,132      1,604 2532 948 1,749 ASTM D 4833-88 Mullen Burst 500*    103123 51 91 ASTM 3786-87 *Maximum test equipment pressure 500 psi - sampleexceeded equipment capability. **<0.70 = minimum weight for the impacthead with no additional weights is 0.70 lbs.

The Impact resistant sheet material of the present invention was alsotested according to the Miami-Dade County Large Missile Impact Test. Topass the Miami-Dade County Large Missile Impact Test, the impactresistant material was tested according to the following tests:

Air infiltration in accordance with Testing Application Standard (TAS)202-94 (ASTM E 283-04);

Water Resistance tests in accordance with TAS 202-94 (ASTM E 331-00);

Structural Performance test in accordance with TAS 202-94 (ASTM E330-02);

Impact Resistance in accordance with TAS 201-94; and

Cyclic tests in accordance with TAS 203-94, the contents of which areall hereby incorporated by reference.

In accordance with the Miami-Dade County Large Impact Missile Test, twowall panels comprising the impact resistant sheet material of Example 1were constructed according to the following specifications and the wall60 illustrated in FIG. 9.

Wall Panel 1

Interior wall (62): 1.2″ Drywall fastened to studs (66) with 1¼″self-tapping screws at each end, 8″ on center;

Studs (66): 31/2″, 18 gauge steel, 24″ on center;

Stud Cavities (67): R-13, 31/2″ Kraft faced fiberglass insulation (notshown);

Exterior sheathing (72): ⅝″ DensGlass Gold fastened to studs 66 with 1¼″self-tapping screws at each end, 8″ on center;

Exterior housewrap (10): Impact resistant sheet material of Example 1,fastened to studs with 1¼″ self-tapping 1″ plastic cap screws, 16″ oncenter;

Metal Lath (68): 33.2 self-furring galvanized, 96×24″ sheets mountedhorizontally with a 4′ overlap, fastened with 11/4″ S 12 screws 6″;

Exterior stucco (70) 3-layers: 1) scratch coat: mixture of sto powderwall stucco and 200# mason sand, approximately ⅓″ thick, notch troweled;2) brown coat: applied with sto powder and mason sand ¾″ thick, thenrodded off smooth; and 3) finish coat: mixture of 50 lb. bag of Ivoryautoclaved lime, ½ bag (46.3 lbs) of Portland cement, 1½ bags (150 lbs)of 30/40 silica.

Wall Panel 2

Wall Panel 2 was constructed similarly to Wall Panel 1, with theexception that the Wall Sample 2 included the following additionalcomponents:

Exterior Foam Board disposed adjacent to the impact resistant layer, thefoam board comprised a 2′×4′×11/2″ polystyrene bead board fastened tostuds with 3″ Windlock wind Devil II fasteners-9/board. Each fastenerwas spotted with primas MD (Dryvit). The exterior of the Wall Panel 2comprised an exterior base coat of Dryvit Primas MD with a layer ofDryvit 40 oz mesh embedded, and a Finish Coat comprised of Dryvit finishwith Dryvit medium base sand pebbles.

The impact resistance of Wall Samples 1 and 2 was tested in accordancewith Testing Application Standard (TAS) 201-94, the content of which ishereby incorporated by reference. In accordance with 6.3.2.1 LargeMissile, the impact resistant test was carried out with a missileprojectile that comprised a solid S4S nominal 2×4 #2 surface drysouthern Pine. The weight of the Missile was 9 lbs, and had a length ofat 7 feet. The missile was fired at various locations on each of thewall panels at a speed of 34 mph as specified in Tables 4 and 7 below. Aspecimen is considered to fail if the impact results in a change incondition of the specimen indicative of deterioration under repeatedload or incipient failure, such as cracking, fastener loosening, localyielding, or loss of adhesive bond.

Upon successfully passing TAS 201-94, Wall Panels 1 and 2 were testedunder a cyclic wind pressure loading in accordance with TAS 203-94, thecontent of which is hereby incorporated by reference. In accordance withthis test, Wall Panels 1 and 2 were subjected to a positive and negativeload to create inward and outward loading on the wall panels. Successfulspecimens have no resultant failure or distress and shall have arecovery of at least 90% over maximum deflection. The results of thetesting are summarized in the Tables below.

Three specimens for each of Wall Panels 1 and 2 were tested. The resultsfor Wall Panel 1 are summarized in Tables 3-5 below.

TABLE 3 TAS202 TEST RESULTS WALL PANEL 1 (+/−30 psf design pressure)ASTM Deflection Deflection Test Load Deflection Center Bottom Load TestMethod Lbs/ft² Top (in.) Span (in) (in) Results Duration AirInfiltration E283 1.57 N/A N/A N/A BDL* N/A Scfm/ft² Preload (Pos.) E330+22.5 0.071″ 0.103″ 0.033″ Pass 30 sec Preload Perm. Set 0 0.029″ 0.035″0.017   0.012″ — Design Load (Pos.) E330 +30 0.112″ 0.164″ 0.056″ Pass30 sec Design Load Perm Set 0 0.042″ 0.056″ 0.031″ 0.020″ — Preload(Neg.) E330 −22.5 0.180″ 0.183″ 0.051″ Pass 30 sec Preload Perm. Set 00.031″ 0.080″ 0.023″ 0.053″ — Design Load (Neg.) E330 −30 0.300″ 0.329″0.091″ Pass 30 sec Design Load Perm. Set 0 0.074″ 0.162″ 0.055″ 0.098″ —Water Resistance E331 +4.5 N/A N/A N/A Pass 15 min. Test Load (Pos.)E330 +4.5 0.126″ 0.299″ 0.117″ Pass 30 sec Test Load Perm. Set 0 0.006″0.068″ 0.052″ 0.039″ — Test Load (Neg.) E330 −4.5 0.283″ 0.358″ 0.128″Pass 30 sec Test Load Perm. Set 0 0.051″ 0.153″ 0.093″ 0.081″ — ForcedEntry TAS202 N/A N/A N/A N/A N/A N/A *Air infiltration was below thedetectable limits of the equipment used.

TABLE 4 TAS201 Large Missile Impact Test Results of Wall Panel 1 Spec-imen Re- No. Impact Locations Speed Observations marks #1 1 Lower Corner50.1 Penetrated Stucco, Pass ft/sec slight tear in wrap 2 Center of WallPanel - 50.3 Penetrated Stucco, Pass 3″ from stud ft/sec slight tear inwrap #2 1 Center of Wall Panel - 50.5 Penetrated Stucco, Pass 3″ fromstud ft/sec slight tear in wrap 2 Upper Corner 49.8 Penetrated Stucco,Pass ft/sec slight tear in wrap #3 1 Lower Corner 50.2 PenetratedStucco, Pass ft/sec slight tear in wrap 2 Center of Wall Panel - 50.4Penetrated Stucco, Pass 3″ from stud ft/sec slight tear in wrap

TABLE 5 TAS203 Cycling Test Results Design Pressure: +/−30 spf PressureSpecimen No. 1 Specimen No. 2 Specimen No. 3 Cycles (lbs/ft²⁾ Def. SetRemarks Def. Set Remarks Def. Set Remarks 600 0-15 N/A N/A Pass N/A N/APass N/A N/A Pass 70 0-18 N/A N/A Pass N/A N/A Pass N/A N/A Pass 1 0-39N/A N/A Pass N/A N/A Pass N/A N/A Pass 600 0-15 N/A N/A Pass N/A N/APass N/A N/A Pass 70 0-18 N/A N/A Pass N/A N/A Pass N/A N/A Pass 1 0-39N/A N/A Pass N/A N/A Pass N/A N/A Pass

Test Results for Wall Panel 2

TABLE 6 TAS202 TEST RESULTS WALL PANEL 2 (+/−30 psf design pressure)ASTM Deflection Deflection Test Load Deflection Center Bottom Load TestMethod Lbs/ft² Top (in.) Span (in) (in) Results Duration AirInfiltration E283 1.57 N/A N/A N/A BDL* N/A Scfm/ft² Preload (Pos.) E330+22.5 0.150″ 0.230″ 0.072″ Pass 30 sec Preload Perm. Set 0 0.016″ 0.034″0.023   0.015″ — Design Load (Pos.) E330 +30 0.185″ 0.325″ 0.115″ Pass30 sec Design Load Perm Set 0 0.026″ 0.060″ 0.052″ 0.021″ — Preload(Neg.) E330 −22.5 0.197″ 0.333″ 0.177″ Pass 30 sec Preload Perm. Set 00.033″ 0.108″ 0.110″ 0.037″ — Design Load (Neg.) E330 −30 0.246″ 0.446″0.237″ Pass 30 sec Design Load Perm. Set 0 0.051″ 0.147″ 0.144″ 0.050″ —Water Resistance E331 +4.5 N/A N/A N/A Pass 15 min. Test Load (Pos.)E330 +4.5 0.306″ 0.653″ 0.347″ Pass 30 sec Test Load Perm. Set 0 0.066″0.206″ 0.252″ 0.047″ — Test Load (Neg.) E330 −4.5 0.269″ 0.680″ 0.424″Pass 30 sec Test Load Perm. Set 0 0.060″ 0.219″ 0.273″ 0.051″ — ForcedEntry TAS202 N/A N/A N/A N/A N/A N/A *Air infiltration was below thedetectable limits of the equipment used.

TABLE 7 TAS201 Large Missile Impact Test Results Wall Panel 2 Spec- imenRe- No. Impact Locations Speed Observations marks #1 1 Lower Corner 50Penetrated Stucco, Pass ft/sec slight tear in wrap 2 Center of WallPanel - 50 Penetrated Stucco, Pass 3″ from stud ft/sec slight tear inwrap #2 1 Upper Corner 50 Penetrated Stucco, Pass ft/sec slight tear inwrap 2 Center of Wall Panel - 50 Penetrated Stucco, Pass 3″ from studft/sec slight tear in wrap #3 1 Lower Corner 50 Penetrated Stucco, Passft/sec slight tear in wrap 2 Center of Wall Panel - 50 PenetratedStucco, Pass 3″ from stud ft/sec slight tear in wrap

TABLE 8 TAS203 Cycling Test Results Design Pressure: +/−30 spf PressureSpecimen No. 1 Specimen No. 2 Specimen No. 3 Cycles (lbs/ft²⁾ Def. SetRemarks Def. Set Remarks Def. Set Remarks 600 0-15 N/A N/A Pass N/A N/APass N/A N/A Pass 70 0-18 N/A N/A Pass N/A N/A Pass N/A N/A Pass 1 0-39N/A N/A Pass N/A N/A Pass N/A N/A Pass 600 0-15 N/A N/A Pass N/A N/APass N/A N/A Pass 70 0-18 N/A N/A Pass N/A N/A Pass N/A N/A Pass 1 0-39N/A N/A Pass N/A N/A Pass N/A N/A Pass

In addition to the wall structures above, wall samples were tested inwhich the wall included an exterior surface comprising vinyl siding andfiber cement board. The test results are summarized in Table 9 below.

The wall structures were impacted by a 9 pound two-by-four (“2×4”)traveling at 34 mph in accordance with Miami-Dade County Large MissileImpact Test (TAS-201). Wall panels 3-10 were not tested with cyclic windpressure loading in accordance with TAS 203-94. The wall panels inaccordance with the invention includes the impact resistance sheetmaterial of the present invention in which

The following materials were used in the wall samples described in Table9 below:

Vinyl siding available from Georgia Pacific, product number 135-WH;

½″ Styrofoam sheathing available from Dow under the trademark DowStyrofoam™, or foam boards available from Johns Manville;

R-13 building insulation available from Johns Manville: JM kraft basedbatts or unfaced batt;

DensGlass sheathing available from Georgia-Pacific under the trademarkDensGlass Gold®

Impact resistant sheet material is the same that used in Wall Panels 1and 2 discussed above.

TABLE 9 Panel Description (4-ft. × 8-ft. Sample No. Wood Wall StudConstruction) Test Results Wall Panel 3 Vinyl Siding Failed(Comparative) ½ in. Dow Styrofoam sheathing R-13 building insulation “2× 4” wood studs 16″ on center ½ in. gypsum drywall. Wall Panel 4 VinylSiding Passed Impact Resistant Sheet Material ½ in. Dow Styrofoamsheathing R-13 building insulation “2 × 4” wood studs 16″ on center ½in. gypsum drywall. Wall Panel 5 Vinyl Siding Failed (Comparative) ¾ in.expanded polystyrene foam ⅝ in. GP DensGlass sheathing “2 × 4” woodstuds 16″ on center R-13 building insulation ½ in. gypsum drywall. WallPanel 6 Vinyl Siding Passed ¾ in. expanded polystyrene foam ⅝ in. GPDensGlass sheathing Impact Resistant Sheet Material R-13 buildinginsulation “2 × 4” wood studs 16″ on center ½ in. gypsum drywall. WallPanel 7 Vinyl Siding Passed ¾ in. expanded polystyrene foam ImpactResistant Sheet Material ⅝ in. GP DensGlass sheathing R-13 buildinginsulation “2 × 4” wood studs 16″ on center ½ in. gypsum drywall. WallPanel 8 Vinyl Siding Failed (Comparative) ½ in. plywood sheathing R-13building insulation “2 × 4” wood studs 16″ on center ½ in. gypsumdrywall. Wall Panel 9 Vinyl Siding Passed Impact Resistant SheetMaterial ½ in. plywood sheathing R-13 building insulation “2 × 4” woodstuds 16″ on center ½ in. gypsum drywall. Wall Panel 10 Vinyl SidingPassed ½ in. plywood sheathing Impact Resistant Sheet Material R-13building insulation “2 × 4” wood studs 16″ on center ½ in. gypsumdrywall. Wall Panel 11 Hardiplank ™ fiber cement board Passed ImpactResistant Sheet Material ⅝ in. GP DensGlass sheathing R-13 buildinginsulation “2 × 4” steel studs 16″ on center ½ in. gypsum drywall. WallPanel 12 Hardiplank ™ fiber cement board Failed (Comparative) ⅝ in. GPDensGlass sheathing R-13 building insulation “2 × 4” steel studs 16″ oncenter ½ in. gypsum drywall.

From the test results in Table 9, it can be observed that the impactresistant sheet material of the present invention was able to provideimpact resistance to wall structures having vinyl siding as an exteriorcovering.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theinvention pertains having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. An impact resistant sheet material comprising: a moisture vaporpermeable, water-impermeable, polymeric barrier layer having a hydroheadof at least 55 cm and a moisture vapor transmission rate of at least 35g/m²/day; and an impact resistant layer attached to the barrier layer,the impact resistant layer comprising a fabric layer having at least twopluralities of strands that extend in different directions and intersecteach other, the impact resistant layer having a tensile strength of atleast 445 Newtons, an elongation that is between 2 and 20 percent, andan Impact Resistance as measured by the Free-Falling Dart Method ofgreater than about 0.7 pounds.
 2. The impact resistant sheet material ofclaim 1, wherein the impact resistant layer has an elongation that isbetween 5 and 15%.
 3. The impact resistant sheet material of claim 1,wherein the impact resistant layer has an elongation that is between 5and 12%.
 4. The impact resistant sheet material of claim 1, wherein thebarrier layer comprises a nonwoven or woven material.
 5. The impactresistant sheet material of claim 1, wherein the barrier layer comprisesa nonwoven substrate comprising polymeric fibers randomly disposed andbonded to one another, and a breathable polymeric film layer overlyingone surface of the nonwoven substrate and intimately bonded thereto. 6.The impact resistant composite sheet material of claim 5, wherein thefilm layer comprises an extrusion coated polyolefin, and the nonwovensubstrate comprises substantially continuous spunbond polypropylenefilaments.
 7. The impact resistant sheet material of claim 1, whereinthe barrier layer comprises a fibrous substrate having a surface towhich a breathable monolithic polymeric film layer is adhered thereto.8. The impact resistant sheet material of claim 7, wherein the fibroussubstrate is selected from the group consisting of spunbond webs, wovenslit films, carded webs, meltblown webs, flashspun webs, woven, andextruded webs.
 9. The impact resistant sheet material of claim 1,wherein the sheet material has a Mullen burst strength of at least 175pounds and an Impact Resistance as measured by the Free-Falling DartMethod of greater than about 1 pound.
 10. The impact resistant sheetmaterial of claim 9, wherein the sheet material has an Impact Resistanceas measured by the Free-Falling Dart Method of greater than 2 pounds.11. The impact resistant sheet material of claim 1, wherein the impactresistant layer includes a first plurality of strands that extend in afirst direction, a second plurality of strands that extend in a seconddirection that is different than the first direction, and third andfourth pluralities of strands that both extend at an angle with respectto the first plurality of strands and are oriented at opposite angleswith respect to each other so they intersect each other in an X-likepattern.
 12. An impact resistant sheet material comprising a moisturevapor permeable, water impermeable composite sheet material havingbarrier properties making it suitable for use as a housewrap, the sheetmaterial comprising: a fibrous substrate; a breathable polymeric filmlayer overlying one surface of the substrate and intimately bondedthereto, the film layer having a moisture vapor transmission rate (MVTR)of at least 35 g/m²/day at 50% relative humidity and 23° C. and ahydrostatic head of at least 55 cm; and an impact resistant layerattached to a surface of the substrate opposite the film layer, theimpact resistant layer comprising a fabric having at least twopluralities of intersecting strands that extend in different directionswith respect to each other, wherein the impact resistant layer has atensile strength of at least 445 Newtons and an elongation that is lessthan 20 percent and an Impact Resistance as measured by the Free-FallingDart Method of greater than about 2 pounds.
 13. The impact resistantsheet material of claim 12, wherein the impact resistant layer has anelongation that is between about 6 and 10%.
 14. The impact resistantsheet material of claim 12, wherein the impact resistant layer has atensile strength that is from about 600 to 1200 N.
 15. A method ofconstructing an impact resistant wall structure comprising fastening anexterior surface of a sheathing material mounted on an exterior side ofthe wall structure with an impact resistant sheet material, the impactresistant sheet material comprising a moisture vapor permeable,water-impermeable polymeric barrier layer having a hydrohead of at least55 cm and a moisture vapor transmission rate of at least 35 g/m²/day;and an impact resistant layer attached to the barrier layer, the impactresistant layer comprising a fabric layer having at least twopluralities of strands that extend in different directions and intersecteach other, the impact resistant layer having a tensile strength of atleast 445 Newtons, an elongation that is between 2 and 20 percent, andwherein the wall structure is able to successfully withstand an impactfrom a projectile comprising a 9 pound, 7 foot two-by-four traveling ata speed of at least 34 miles per hour without penetration of the wallstructure.
 16. The method of claim 15, wherein the impact resistantlayer has an elongation that is between 5 and 15%.
 17. The method ofclaim 15, wherein the impact resistant layer has an elongation that isbetween about 6 and 10%.
 18. The method of claim 15, wherein the wallstructure is capable of passing the Large Missile Impact Resistance Testaccording to TAS 201-94, and the Cyclic Wind Pressure Loading Testaccording to TAS 203-94.
 19. The method of claim 15, the barrier layercomprises a fibrous substrate having a surface to which a breathablepolymeric film layer is adhered thereto.
 20. The method of claim 19,wherein the fibrous substrate is selected from the group consisting ofspunbond webs, woven slit films, carded webs, meltblown webs, flashspunwebs, woven, and extruded webs.